Note: Descriptions are shown in the official language in which they were submitted.
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COLLAPSIBLE CONTAINER
BACKGROUND OF THE INVENTION
The present invention generally relates to molded
plastic containers of the type commonly used for a
variety of purposes including storage of both food items
and non-food items, such containers preferably being
adapted to receive an appropriate seal or lid. More
specifically, the invention is concerned with containers
of this type which, rather than being of a rigid
construction as with a conventional bowl, are collapsible
or foldable to a compact position when empty to
facilitate convenient storage.
Such containers, in the form of cups, bowls, and the
like, are generally known in the art and take many forms.
These include collapsible cups or glasses wherein the
glass is formed of telescopically stacked annular wall
elements which slide relative to each other between a
fully extended position and a collapsed position. As the
wall elements are not integrally formed and slide freely
relative to each other, there is a substantial
possibility of leakage, and use other than as a temporary
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drinking vessel is not practical. Another form of
collapsible container more pertinent to the present
invention is illustrated in Patent No. 5,439,128, issued
to Fishman on August 8, 1995. In the Fishman container,
the wall elements are integrally molded and consist of a
series of both vertical and angled elements alternately
stacked to define the container wall. The elements, at
the angular joint therebetween, are integrally joined by
thin film hinges about which the wall elements fold. The
actual downward folding and collapsing of the Fishman
elements requires that the elements flex in order to
accommodate the folding motion. This necessity for an
actual flexing of the elements themselves, in addition to
the folding at the film hinges, appears to be so
significant as to, at least in some instances as
illustrated in Figure 3 of Fishman, require significant
central relief grooves in each of the inclined wall
elements which would appear to cause an inherent
weakening of these wall elements. It will also be noted
that, in the Fishman container when collapsed, the
alternate vertical wall elements of the open container
retain their vertical orientation perpendicular to the
base wall. As such the Fishman container is clearly not
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susceptible to injection molding in the collapsed
position as would be commercially advantageous due to
great economies in mold production and molding
procedures.
SUMMARY OF THE INVENTION
A principal object of the present invention is to
provide a collapsible container which presents or forms a
substantially rigid receptacle in its open or expanded
position and which, with an appropriate lid or seal snap-
fit thereto, provides a practical watertight storage
container for, as an example, an appropriate foodstuff or
the like. The container is very convenient and provides
a particularly desirable portable solution for food "on-
the-go", such as at picnics, lunches for those who take
their own lunch to work, and other instances wherein
temporary storage is desired. The collapsible nature of
the container, collapsing to a substantially completely
compacted configuration of minimal height, particularly
with a seal mounted thereon to confine any residue in the
now empty container, allows the used container to be
conveniently stored or packed away in a "brown bag",
knapsack, picnic hamper, or the like, for subsequent
cleaning and reuse.
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In furtherance of the principal object of the
invention, it is also an object of the invention to
provide a method of molding the container in its
collapsed position as a means of achieving maximum
economies in mold apparatus and procedures, and in
providing a molded product which is compact yet fully
expandable to a relatively rigid self-sustaining
position.
A significant aspect of the container of the
invention is its capability to fold open in increments,
one section at a time, to vary the capacity thereof and
at the same time maintain itself in any incrementally
folded position.
Other desired features of the invention include
providing a container which can be washed in a dishwasher
in its folded position and stacked therein in the same
manner as conventional dishes, a container which stays
open when in use and stays closed in storage, and a
container which maximizes usable space for packing in a
shipping carton as well as storage in the home.
In order to achieve the improved and highly
practical container of the invention, the peripheral wall
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of the container, extending between a substantially rigid
base and a substantially rigid top ring adapted to
receive a snap-fit seal, includes a series of generally
rigid annular or peripherally continuous wall sections
joined to adjacent sections at fixed annular apex forming
joints which are alternately inwardly and outwardly
directed relative to the interior of the container.
These sections have annular portions therebetween that
are relatively flexible. The wall sections, in the
expanded or open position of the container, are
themselves alternatively angled inward and outward
relative to the interior of the container and relative to
the vertical, with the wall sections, sequentially upward
from the base to the top ring, each being generally
diametrically or peripherally progressively greater than
the base. The configuration thus formed for the expanded
container will be that of an inverted truncated cone with
the wall sections basically outwardly stepped upward from
the base. This in turn allows for a direct downward
collapsing of the wall sections into concentric
surrounding relation to the base with the top ring
surrounding the collapsed folded wall sections.
The actual folding of the wall sections relative to
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each other occurs within a flexure portion at an apex
area between the sections where each of the wall sections
joins the wall section or sections immediately adjacent
thereto and is of a thickness less than that of the
thickness of the sections to each side thereof. The
thicker sections are both more rigid than the flexure
portions and of substantially more limited flexibility.
The thinner portions, in the expanded position of the
container, form arcuate continuations of the thicker wall
sections, forming an arc of greater than 90 degrees and,
until physically moved over center during a collapsing of
the container, provides a substantial degree of rigidity
to the wall sections for the full height of the container
wall. Upon the application of a positive physical force
collapsing the top ring and base toward each other, the
flexible portions between the wall sections will flex
laterally in the direction of the fold in the manner of a
flexible hinge with this flexure providing for both the
actual folding and at the same time, minimizing any
tendency for the wall sections to want to laterally flex
or move as the wall sections collapse about each other.
Each of the flexure zones formed by the thinner portions
is bordered along each edge thereof by adjacent thicker
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wall sections. Once the arc of the flexure zone is
reduced to less than 90 degrees, moving over center, the
inherent resistance to the movement of the flexure zone
is overcome and the collapsed zone assumes a dome-like
configuration of less than 90 degrees. In moving from
the closed to the open state, or vice-versa, each flexure
zone is twisted and slightly distorted until it overcomes
its stable position and flips to the other position.
A collapsed molded container in accordance with the
invention is such that opposed rigid wall portions define
a generally triangular interstitial space formed by two
walls diverging from the vertical in a range of from.
about 8 to about 40 . However, for reasons that shall
become apparent hereinbelow, a preferred range is from
about 10 to about 16 .
Expansion of the container from its collapsed
position will involve a downward push or pull on the base
as the top ring is moved vertically upward therefrom. As
the flexure portions unfold and move to arcs of greater
than 90 degrees, the wall will tend to rigidify and in
effect lock the container in the open position.
Further features, objects and advantages of the
invention will be noted as the construction and details
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of the invention are more fully hereinafter set forth.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a top perspective view of the container
of the invention in its open or expanded position;
Figure 2 is a top perspective view of the container
fully collapsed;
Figure 3 is a transverse cross-sectional view of the
expanded container;
Figure 4 is a transverse cross-sectional view of the
collapsed container;
Figure 5 is an enlarged detailed view of the area
designated A in Figure 3;
Figure 6 is an enlarged detailed view of the area
designated B in Figure 4;
Figure 5A is a view similar to Figure 5 illustrating
a modified construction;
Figure 6A is a view similar to Figure 6 illustrating
the modified construction;
Figures 7, 8 and 9 sequentially illustrate one
manner of opening, or closing the wall sections utilizing
a twisting or sequential ratchet action;
Figure 10 is a cross-sectional view similar to
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Figure 4 with the seal snap-fitted to the collapsed
container;
Figure 11 is a cross-sectional detail of a modified
pressure bump in the base provided with a pull bar; and
Figures 12-22 illustrate a further embodiment and
sequentially correspond to Figures 1-11.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the drawings, the features of the embodiment of
Figs. 1-11 are referred to by two digit numbers. Similar
features in the embodiment of Figs. 12-22 are referred to
by the same numbers with the number 1 as a prefix.
Referring now more specifically to the drawings, the
collapsible container 10 comprises a base 12, a top ring
14 and a folding wall 16 extending therebetween. The
base 12 is a substantially rigid member including a
bottom 18 with a peripheral upstanding base wall 20. The
base, which may be flat, preferably includes a central
slightly upwardly extending pressure area or bump 24 of
any appropriate configuration, such as a dome, to assist
in expanding the container as shall be described
subsequently. The base will also preferably have a
series of small foot defining knobs 26 or a continuous
foot rib, not shown, depending from the base bottom 18.
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The top ring 14 includes a continuous or annular
ring wall 28 with a peripheral horizontally outwardly
directed flange 30 at approximately mid-height on the
ring wall 28. The top ring 14, similarly to the base 12,
is substantially rigid and is of a greater diameter or
other non-circular cross-sectional area than the base 12
to encircle the base in the collapsed position of the
container, as in Figure 4, sufficiently outward thereof
to accommodate the folded container wall therebetween.
The top ring flange 30 provides additional lateral
stiffness to the top ring, and a convenient means for
handling the bowl, especially when filled. In addition,
the ring flange 30, when the collapsed bowl is to be
opened, allows a user to easily engage fingers about and
under this flange 30 while pressing downward with the
thumbs on the base domed pressure area 24 to forcibly
vertically expand the base and top ring relative to each
other. As an alternative to pressure on area 24,
particularly with a large bowl, pressure can be applied
sequentially about the base bottom 18 immediately
adjacent the base wall 20 peripherally thereabout. As
desired, and as will be best noted in Figures 1 and 2,
the ring flange 30 can be slightly outwardly extended or
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enlarged at diametrically opposed portions to define
gripping handles 32.
The molding of the base and top ring as separate
entities from the wall is a preferred method of molding
enabling the provision of substantially greater rigidity
to these components relative to the wall sections,
wherein the actual extending and collapsing action
occurs, by utilization of polymers of differing degrees
of rigidity, and/or flexibility.
The container side wall 16 is formed of a series of
annular or peripherally continuous wall elements or
sections 34, the lowermost section encircling and being
intimately bonded, such as autogenously during a multi-
component molding procedure, to the wall 20 of base 12
and seated on a support shoulder 21 slightly above the
base bottom.
In the embodiment of Figure 5A, the lowermost or
bottom section, being of a height slightly less than the
remaining sections thereabove, is integrally joined to a
thin upwardly projecting base portion 22 which, as the
container wall folds, will define a flexure zone between
this lowermost wall section and the base.
The wall sections 34, upward from engagement of the
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lowermost section with the base, are alternately inclined
outwardly and inwardly relative to the interior of the
container and to the vertical with each section joined to
the section immediately thereabove at alternating
outwardly and inwardly directed apexes or apex portions
forming, respectively, angle joints as generally
designated at 36 and 38.
Noting Figure 5, the uppermost or top section 34 is
joined by a flexure portion to an upwardly directed
collar 37 received and intimately fixed within the lower
portion of the ring wall 28, for example in the manner
suggested with regard to the lowermost section. In the
embodiment of figures 5A and 6A, the uppermost section 34
is integral or otherwise intimately peripherally joined
to the lower edge portion of the top ring 14.
Each of the alternately inclined wall sections,
noting the open container, is of a predetermined
thickness and of limited flexibility relative to flexure
zones or portions 40 joining adjacent sections 34. The
flexure portions 40 are relatively thinner than the
sections 34 and substantially equal in thickness to the
extending portion 22 of the base in Figure 5A. The
flexure zones or portions 40 generally define the angled
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joint, 36 or 38, between each section and the section
immediately adjacent thereto. As noted, the height of
these reduced thickness portions 40 is substantially less
than the height of the sections 34. These flexure zone
portions 40, in the expanded or open position of the
container, again noting Figure 5, form, with regard to
the outwardly inclined wall sections 34, continuations of
the inner face of the corresponding portion 34
therebelow, and, with regard to the inwardly inclined
wall sections, are continuations of the outer face of the
corresponding wall section. So formed, the thicker wall
sections to each side of these flexure zone portions 40,
and the angle thereof, inherently defining the direction
of the folding action, note in particular the folding
sequence suggested in Figure 8. It will also be
appreciated that, prior to folding, the flexure zones 40
and the positioning of these zones 40 between adjacent
sections, provides a degree of over center stability to
prevent inadvertent collapse of the wall 16. This
stability can only be overcome by a applying sufficient
positive vertical pressure, forcing the top ring and base
vertically toward each other to effect an over center
movement of the flexure zones 40 and a "snap action"
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folding action of the zones to the collapsed position.
Upon initiating the folding action, each involved flexure
zone 40 distorts slightly until it moves to what might be
considered an over center position, at which point it
flips to the folded position. In this manner, any
tendency for the container to self close or collapse
accidentally, particularly with goods within the
container, is minimized.
As will be noted in the drawings, the adjacent
sections 34, in the collapsed position of the container,
form oppositely facing V-shaped or triangular openings.
The center line of each V-shaped opening is generally
perpendicular to the horizontal plane of the collapsed
container. This structure is significant in allowing the
injection mold to separate to eject the molded piece.
The angle of divergence between adjacent collapsed
Oections 34 has an overall possible range of 8 to 40 ,
with the. preferred range being 10 to 16 . An angle of
10 is considered optimum in achieving a desired balance
between rigidity of the container in the open position
and the force necessary to collapse or expand the
container. This angle is also considered, as a practical
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matter, to be the smallest angle that will allow
consistent ejection of the molded piece from the mold.
As will be appreciated, as the angle increases, the
rigidity of the open container decreases.
With particular attention to Figures 7-9, it will be
seen that, if desired, both the opening and collapsing of
the container can be facilitated by applying pressure
sequentially about the container or by rotating the
container as pressure is applied to provide a stepping or
ratcheting effect on the wall sections 34 rather than by
snap positioning each flexure zone in its entirety at one
time.
Figure 9 is of particular interest in showing the
container partially folded or unfolded for use when a
reduced capacity is desired or required. In such a
position, the container is fully functional to receive
and store foodstuffs and the like, and the seal 42, as in
the open container of Figure 3, is also fully functional
in that the top ring is dimensionally stable in every
position of the container.
Noting in particular Figure 3, it will be seen that
the general outward stepping of the sections upward from
the base to the top ring forms, in the open container, a
CA 02488313 2005-01-25
generally inverted truncated conical configuration.
Again noting Figures 7-9, as the container is
vertically collapsed, the flexure zones 40 fold between
adjacent sections to assume a generally domed
configuration. Thus the adjacent wall sections are
folded to bring the thicker major height of the sections
into concentric generally parallel relation to each
other, with the angle between adjacent sections
preferably being approximately 100 to 16 , with the
sections laterally aligned and surrounding said base
between the base wall 20 and the top ring wall 28. This
will best be seen in the cross-sectional detail of Figure
6.
Noting Figures 3, 9 and 10, it will be seen that the
seal 42 is capable of being snap-fitted to the top ring
14 in an appropriate manner in any position assumed by
the container. To facilitate this engagement, the upper
portion of the top ring wall 28, above the
circumferential flange 30, may be slightly outwardly
inclined for reception within a peripheral downwardly
directed groove on the seal. It is to be appreciated
that inasmuch as the folded wall sections are, in any
position of the container, positioned concentrically
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inward of the substantially rigid top ring 14, the seal
42 functions as an appropriate closure for the open
container, the partially expanded container, and the
collapsed container wherein a compacted storage position
is achieved.
As previously noted, when the container is to be
opened prior to use, one need merely engage fingers about
the peripheral flange 30 of the top ring and, with one or
both thumbs, exert a downward pressure on the bottom push
bump 24 projecting upwardly from the center of the base
bottom 18. Alternately, pressure can be exerted on the
bottom itself sequentially about the periphery thereof.
Further, rather than relying on direct pressure on the
bump 24 or bottom 18, and noting Figure 11, a cross bar
44 can be provided diagonally across the concave recess
or depression formed by the bump in the lower face of the
bottom 18. This cross bar 44 can be physically gripped by
the user's fingers for a direct downward pull on the
container base, moving the base downward relative to the
top ring and expanding the wall sections.
Again referring to Figure 6, it will be noted that
the lowermost folding wall section 34 will act as a limit
to the downward collapsing of the remaining wall sections
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and top ring relative to the base wall, retaining the
sections and top ring slightly above a support plane
defined by. the base bottom and support feet thereon
whereby support of the container, both expanded and
collapsed, is on the base and base feet rather than on
the much thinner flexure zones.
Referring now more specifically to the embodiment
illustrated in Figures 12-22, the basic components of
this embodiment substantially duplicate those of the
previously described embodiment, and as such, have been
designated by the same reference numbers with the number
1 as a prefix. Thus, the container 110 is comprised of a
base 112, a top ring 114, and a folding wall 116 of
alternating rigid wall sections 134 and flexure zones or
portions 140.
The container 110, as with the first embodiment,
both expands and collapses in the previously described
manner and, in the collapsed position, is so configured
as to allow for a practical and preferred molding of the
container in this position. Pursuant thereto, the wall
sections 134, in the collapsed position, define
oppositely facing V-shaped openings where the angle
between the sections, while having a. possible range of 8
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to 40 , will preferably be in the range of 100 to 16 with
an optimum angle of 10 . Each V-shaped opening has the
centerline thereof, extending from the apex defined by
the converging sections 34, perpendicular to the
horizontal plane of the collapsed container. In the
expanded or open position of the container, the wall
sections 134 angle both relative to each other, at
greater than 90 ,.and to the vertical as defined by a
perpendicular to the base.
In order to enhance the folding and unfolding action
of the wall sections 134, each wall section 134, along
the edges thereof, is beveled, as at 135, to provide a
gradual transition area between the wall section 134 and
the adjacent flexure portion 140. This differs from the
rather abrupt transition area of the first embodiment,
note in particular Figures 5 and 6.
As with the first embodiment, the flexure.zone
portions 140, in the open position of the container,
form, with regard to the outwardly inclined wall sections
134 of Figure 16, continuations of the inner face of the
corresponding section 134 therebelow. Similarly, the
flexure zone portions 140, with regard to the inwardly
inclined wall sections 134, are continuations of the
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outer face of the corresponding wall section 134. This
relationship, as previously described, will inherently
tend to define the direction of the folding action, note
in particular the folding sequence suggested in Figure
19, as well as the previously described Figure 8.
With particular reference to Figures 16 and 17, it
will be seen that the bottom wall section 134 is of a
greater height than the wall sections thereabove, and
extends for the full height of the peripheral upstanding
base wall 120. The lower extremity of this lowermost
wall section 134 is turned under the bottom 118 of the
base 112 and engaged within a receiving recess 119, thus
in effect defining a portion of the support plane of the
container. As will be appreciated, the enhanced area of
overlap between the lower portion of the container wall
and the base enhances the joinder therebetween.
The engagement of the container wall to the top ring
is effected by a laterally directed collar 137 joined to
the uppermost wall section 134 by the uppermost flexure
portion 140. The collar 137 includes an upwardly
directed locking bead 139 on the outer edge thereof with
both the collar 137 and bead 139 being received within a
corresponding locking recess found in the base of annular
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ring wall 128. The top ring 114, as with the previously
described ring 14, includes an integral annular outwardly
projecting ring flange 130, providing both lateral
stiffness to the top ring and a convenient means for both
manipulating and handling the bowl. As a means for
facilitating a gripping of the flange, it is proposed
that an integral depending gripping bead 131 be provided
peripherally about the outer edge portion of the flange
130.
A final area of variance between the embodiments
will be seen in Figure 12, and the various cross-
sectional views of the container 110. As will be
appreciated from a comparison of these figures with the
figures of the first embodiment, the base 112 includes a
substantially enlarged central upwardly extending
pressure area or bump 124. This enhances the area upon
which opening pressure, in particular, can be applied,
facilitating the manipulation of the container and at the
same time having a tendency to further strengthen the
otherwise flat bottom 118. As noted in Figure 22, the
bottom push bump 124 can also be provided with a diagonal
cross bar 144 for purposes previously noted with regard
to cross bar 44.
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Also, as described with regard to the first
embodiment, an appropriate seal 142, capable of being
snap-fitted to the top ring 114 can be provided. Such a
seal, in light of the manner of collapsing and expanding
the container with the concentric folded wall sections,
will comprise an appropriate closure for the container
whether fully open, fully collapsed, or partially
expanded.
With reference to Figure 21 in particular, it will
be seen that the downwardly collapsed wall sections 134,
and more particularly the downwardly directed flexure
portions 140 are retained slightly above the support
plane defined by the base bottom and/or support feet,
providing a more stable support and avoiding engagement
of the substantially thinner flexure zones with a support
surface.
The container as described is designed in a
configuration that utilizes a "network" of flexure zones.
It is not an accordion shape that stretches to open and
close like a spring. Instead, the flat storage container
functions to open and close based on a principle of
"opposing angles".
In known expanding containers, the containers are
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generally molded in the open or expanded configurations.
Open is thus the natural state for those containers, that
is those containers would `prefer' to remain open than in
any other position. Thus, when one tries to fold or
collapse these containers, the containers tend to want
to spring back open, that is return to their natural
state. This is not the case with the container of the
invention wherein the container is preferably molded in a
flattened or collapsed position. This is its initial
natural state meaning that the container will initially
prefer to stay in this closed configuration. There are
multiple folds within the network of flexure zones. In
the illustrated embodiment three sets of independently
activating zones are provided (more can be added to
increase capacity if desired). As seen in Figure 9, each
of the independently activatable flexure zones has a
second `natural' or at rest state when open wherein the
fold will prefer to remain open independently of the
remaining folds. In the present structure, both the
action of collapsing the container and the action of
expanding the container require the folds to be
individually manipulated. Positive action is required to
both fold and unfold the container. This can be referred
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to as the principle of "opposing angles". The angle of
the fold in the closed position keeps the fold closed;
the angle of the fold in the open position keeps the fold
open. To move from the closed to the open state or vice-
versa, the flexure zone is twisted and distorted slightly
until it overcomes the opposing angle and then flips to
the other position configuration. This action results
because the diameters of the flexure zones cannot change.
There is no other intermediate position for the fold. It
is either open or closed, or it is being twisted(one side
open and the other side closed). It is not possible in
this construction for an individual section to be, as an
example, half open while maintaining usable capacity. As
previously noted, one easy way to manipulate the flexure
zones is to `ratchet' the container, one side at a time
to a partial or fully open position.
The unique structure of the invention allows the
container to remain flat when in the closed or collapsed
position and remain expanded when in any open or
partially open position. Because of the two `natural'
states for the flexure zones, the container prefers to
remain closed when collapsed flat and prefers to remain
open when expanded. with the independent activation of
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the flexure zones in the network, the container is
capable of opening to fixed partial capacities, because
the container prefers to remain open in these partial
configurations. This is of particular value in
maximizing and optimizing storage space as in a
refrigerator, and dishwasher space when washing.
The collapsible container of the present invention
has been described in the preferred embodiments as
comprising one of molded plastic, i.e. synthetic
polymers, having `separate entities' comprising a base,
top ring and folding wall. The `separate entities' in a
preferred molding method may, for example, be realized by
utilization of molding apparatus that enables multiple
stage molding of the base, top ring and folding wall, and
wherein selection of polymers of varying degrees of
substantial rigidity and/or general rigidity may be
utilized. This also enables the varying of the color or
light transmissivity of the base, top ring and folding
wall.
It will be appreciated that as described in
connection with the embodiment of Figures 5A and 6A, the
container of the present invention may be molded as a
unitary structure in essentially a single molding step.
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In addition, the described preferred difference in
relative rigidity, or general, but more flexible,
rigidity of the base and ring vis-a-vis the folding wall,
may be achieved in a single molding step by selection of
appropriate thicknesses of the several portions. The
possibility also exists to provide molding apparatus
wherein a mold is configured to provide selected areas of
the mold interior with polymers of varying degrees of
rigidity or flexibility for the base, top ring and wall.
It will be appreciated that a mold suitable for
injection molding of the wall portion in a collapsed
condition will require a plurality of concentric annular
interdigitated generally triangular, or V-shaped mold
elements, carried by mold halves, corresponding to the
number of wall sections folded on each other.
The foregoing is considered illustrative of the
principles of the invention. As modifications and
changes may occur to those skilled in the art, it is not
desired to limit the invention to the exact construction
and manner of use as shown and described. Rather, all
suitable
modifications and equivalents may be resorted to as
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falling within the scope of the invention as claimed.
27
